A method is for manufacturing a stator of a rotary electric machine. The method includes; forming a stator core; forming each of cassette coils by concentrically winding rectangular wire for the specified number of turns, each of the cassette coils being formed by applying a shift amount with respect to an axis in a winding direction to a wire shape of at least one of the turns before being attached to the teeth; attaching each of the cassette coils to each of teeth while canceling the shift amount; and forming a wire coil of the rotary electric machine by connecting a winding terminal of one of the cassette coils to a winding terminal of another of the cassette coils.

A conductor shaping apparatus includes a driving device that relatively rotates an upper die and a lower die and integrally rotates the upper and lower dies with respect to a shaping member. The driving device rotates one of the upper and lower dies in a direction from an edgewise bent portion to a distal end of a conductor so as to separate the one of the upper and lower dies from the other. One of the upper and lower dies includes a supporting surface configured to support a side surface of an end portion of the conductor as the edgewise bent portion is formed in the end portion, and a guide surface that is formed to intersect the support surface. The guide surface extends away from the end portion of the conductor in a direction opposite to a bent direction of a flatwise bent portion closest to the edgewise bent portion as it extends away from the supporting surface on an opposite side of a rotational axis.

A method for forming the heads of coils made of rectangular wire so that it fits within the slots of the stator of an electric machine. The method includes receiving a coil having unformed first and second heads separated by first and second legs and applying controlled deformation to yield properly shaped heads. Actuators are provided for causing sequential actuated movements of one of the first and second legs to force the head-forming elements into contact with different portions of the first and second heads while allowing selective free movements of the other leg in response to the actuated movements.

An apparatus for manipulating a material is provided. The apparatus may comprise a magnetic device arranged in a three-dimensional configuration. The apparatus may comprise a surface on which at least one carrier is configured to move. The magnetic device may be configured to provide a magnetic field for driving the carrier on the surface to manipulate a material. The apparatus may comprise a controller configured to control the magnetic device to modulate the magnetic field. The controller may be further configured to detect a position and/or motion of the carrier.

A coil segment forming apparatus, a coil segment forming method and a manufacturing apparatus of an electrical rotating machine, whereby coil segments with various kinds of shape can be formed without exchanging a press die, and it is not necessary that a lot of coil segments of various kinds of shape are preliminarily formed and stocked is provided. The coil segment forming apparatus includes a first bending section for bending in the same plane a linear wire rod into a predetermined shape consisting of a pair of slot insertion portions that are substantially parallel to each other and a linking portion for connecting the pair of slot insertion portions. The first bending section has a plurality of jigs arranged on the same plane for supporting the wire rod, and a plurality of drive mechanisms for moving respectively the plurality of jigs on the same plane so that the wire rod is formed in the predetermined shape based on moving amounts respectively set depending on shape conditions of the coil segment to be formed.

Systems, computer readable media storing instructions, and computing device-implemented methods include receiving one or more signals that represent an angular speed of a permanent magnet electric motor of a hybrid electric vehicle, receiving a signal representing a voltage from the electric motor, determining if the angular speed is within a predetermined threshold, calculating an error angle representing a correction factor for an alignment of the electric motor based on a ratio of the voltage and the angular speed, determining if the error angle indicates that the motor is installed in a correct or an incorrect orientation, and adding an orientation correction factor to the error angle.

A casting device having a casting mold and a core for producing a helical casting is described. The may have an expendable core that can be dissolved after the casting process. Advantageous effects of the device and process can be achieved by virtue of the fact that the female mold for accommodating the helical casting during the casting process is formed completely within the outer contour of the core, the female mold being delimited by the core and, at the peripheral boundary surfaces of the female mold, by the casting mold.

A coil includes a series of turns constituted by a first turn to an n-th turn of a conductive wire having a quadrangular cross-section, where the conductive wire is wound in a spiral shape and is stacked in a vertical direction, and n is an integer equal to or greater than 3. In addition, at least a part of the conductive wire of the first turn to the n-th turn is provided with a deformed part whose shape is different from shapes of the other parts. Further, the first turn and the n-th turn are on the both end parts of the series of turns. In addition, at each of the first turn and the n-th turn, the deformed part makes an outer surface positioned on an opposite side with respect to a center of the series of turns extend in a flush manner along a plane intersecting the series of turns.

An electromagnetic machine includes a rotor and a stator. The rotor is adapted to rotate about an axis. The stator includes a support structure, a plurality of bobbins engaged to the support structure, and a plurality of electric coils with each one wound about a respective bobbin of the plurality of bobbins.

A conductor shaping apparatus includes a driving device that relatively rotates an upper die and a lower die and integrally rotates the two dies with respect to a shaping member. The driving device rotates one of the upper and lower dies in a direction from an edgewise bent portion to a distal end of a conductor. One of the upper and lower dies includes a supporting surface configured to support a side surface of an end portion of the conductor as the edgewise bent portion is formed in the end portion, and a guide surface that is formed to intersect the support surface. The guide surface extends away from the end portion of the conductor in a direction opposite to a bent direction of a flatwise bent portion closest to the edgewise bent portion as it extends away from the supporting surface on an opposite side of a rotational axis.